2010 HOYT MEMORIAL LECTURE
HOW CAN WE BECOME A PRACTICAL GREEN FOUNDRY INDUSTRY? G. Gigante
ThyssenKrupp-Waupaca, Waupaca, WI, USA Copyright © 2010 American Foundry Society
Keywords: recycling, green technology, waste reduction, energy reduction, energy use, energy efficient
Introduction
Foundries have long looked at themselves as the nation’s recyclers. Since metals were first poured, it was recognized that recycling old iron castings was the easiest manner to remake another casting and reuse society’s unwanted cast articles. Later, steel scrap was introduced into our charge mixes as an additional feedstock to achieve the same goal. This recycling trend extended to most other metals cast, in- cluding aluminum, copper and lead.
Today, because of our recycling of metals, most foundries have long considered themselves a part of the green technol- ogy movement before the term “green” was even coined. In reality, the foundry industry has only scratched the surface of being green and has yet to achieve the higher level of sustainability that the future will demand. We are an energy intensive industry, handle massive quantities of processed waste materials often destined for landfills, and have the po- tential to emit a large quantity of carbon dioxide and other pollutants into the atmosphere.
Green Technology
What is a green technology? Green technology encompass- es a large body of concepts whose definition may vary by group or industry. Synonymous with sustainability, green technology is broadly defined as technology that when properly implemented, allows an organization to meet its present needs without compromising its future needs. Green technology can include energy and material waste reductions in the manufacturing process, and the use of al- ternative manufacturing technologies with the least impact to human health, the earth, and its natural resources. Sus- tainability and the application of green technology means finding smarter ways to use our finite natural resources, both in manufacturing materials and in the energy reserves used to manipulate them.
Waste reductions in the manufacturing process can take on many forms. All waste streams that leave the facility, re-
Due to political and global concerns, energy reduction has led the green assault. Home lighting, heating, and appliances now have a host of green products available for use in our homes. The cars we drive are making strides toward greater fuel economy and the reduction of the resulting emissions. Perhaps the most visible change in our lifestyles is the pack- aging of the goods we buy. Virtually all the packaging used in getting goods to the consumer are now at least partially comprised of recycled materials. Additionally, the practice of bringing groceries home in reusable tote bags is becoming more accepted.
Greening the Industry
What about our industry? Have we given green technology the attention it requires? Many of us may believe the idea that simply recycling our region’s available scrap makes us a green industry and we need not go farther.
gardless of media, must be evaluated for potential reduc- tions. Manufacturing processes need to be as self-contained as possible, with process materials recycled without an un- due addition of energy demand.
Energy reductions in the manufacturing process pose sig- nificant potential improvements in total energy usage and the reduction of carbon emissions resulting from the com- bustion of fossil fuels. To become greener, one must find ways to increase the efficient use of energy in the complete manufacturing process, and not merely shift energy use up or down the manufacturing stream.
Today the term “green” is ever before us. It’s enthusiasti- cally proclaimed in TV commercials, magazine ads, product packaging, and news articles. Green technology has spawned an entire new industry complete with consultants, engineer- ing disciplines, university curriculums, books, magazines, web sites, investment opportunities and even its own dedi- cated TV channel. Whether we fully realize it or not, every aspect of our lives is now being affected by the existence of green technology and its future development.
International Journal of Metalcasting/Summer 10
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